Collapsible pack with inner flap

ABSTRACT

A collapsible pack and associated blank assembly, comprising a base portion, lid portion and an inner flap portion, the base portion comprising a bottom panel (A 2 ), opposing front (A 1 ) and rear (A 3 ) panels and opposing side walls (D 3 ,E 3 ) wherein the front panel, rear panel and the side walls are each hingedly connected to the bottom panel, the lid portion comprising a top panel, and the inner flap portion comprising a rear panel, wherein the inner flap portion and the lid portion are each hingedly connected to the base portion rear panel.

The present invention relates to a collapsible pack and, in particular, to a flat-pack box and also to a blank assembly formable into a collapsible pack.

Retail staff are under pressure to serve as many customers as possible, in as short a time as possible, and to focus their attention on the client they are serving at the same time. Likewise, businesses are under continual pressure to offer high quality products, which are well presented at the point of sale and/or to provide high quality packaging that is fit for purpose. Furthermore, there is often limited storage space in business premises, retail spaces and in the logistics chain on a product's journey from factory to consumer.

Typical boxes, lids and fitments require some form of transportation or storage. In addition, freight is charged by volumetric weight (volume and weight being used in the cost calculation), so shipping assembled boxes and packaging means paying for shipping the contents which may include a large volume of air in addition to the packaged products themselves. In order to overcome one or more of the drawbacks of known packaging, the invention proposes a re-foldable, flat-pack box which is simple and quick to erect.

This invention is such that the box may be assembled and disassembled quickly and easily without the need to use glue or adhesives during folding (or unfolding).

According to a first aspect, the present invention provides a collapsible pack comprising a base portion, a lid portion and an inner flap portion, the base portion comprising a bottom panel, opposing front and rear panels and opposing side walls wherein the front panel, rear panel and the side walls are each hingedly connected to the bottom panel, the lid portion comprising a top panel, and the inner flap portion comprising a rear panel, wherein the inner flap portion and the lid portion are each hingedly connected to the base portion rear panel.

In embodiments of the invention, the lid portion top panel is hingedly connected to the base portion rear panel.

During assembly of the pack, the inner flap portion rear panel is folded about the hinge line connecting same to the base portion rear panel so as to cover the base portion rear panel. In this way, in the erected pack, the inner flap portion rear panel reinforces the rear face of the pack giving further strength to the assembled pack.

In preferred embodiments, the inner flap portion rear panel is hingedly attached to the base portion rear panel. More specifically, the inner flap portion rear panel is hingedly attached to, or proximate to, an edge of the base portion rear panel. More specifically still, when hingedly attached proximate to an edge of the base portion rear panel, the inner flap portion rear panel is attached to the inner face of the base portion rear panel. In embodiments of the invention, the lid portion further comprises a side panel hingedly connected to the lid portion top panel. It is preferred that, in the fully assembled pack, the lid portion side panel will lie against the base portion front panel of the pack.

In embodiments of the invention, the inner flap portion further comprises a bottom panel hingedly connected to the inner flap portion rear panel. More specifically, the inner flap portion bottom panel is hingedly connected to a free edge of the inner flap portion rear panel, which free edge is opposite the edge of the inner flap portion rear panel hingedly connected to the base portion rear panel.

During assembly of the pack, the inner flap portion bottom panel is folded about the hinge line connecting same to the inner flap portion rear panel so as to lie against the base portion bottom panel. In this way, in the erected pack, the inner flap portion bottom panel reinforces the bottom face of the pack giving further strength to the assembled pack.

In embodiments of the invention, the pack further comprises a base portion inner front panel. More specifically, the base portion inner front panel is hingedly connected to the base portion front panel. During assembly of the pack, the base portion inner front panel is folded about the hinge line connecting same to the base portion front panel so as to lie against the base portion front panel. In this way, in the erected pack, the base portion inner front panel, when present, reinforces the front face of the pack giving further strength to the assembled pack.

In embodiments of the invention, the pack further comprises first, second, third and fourth pairs of base side wall flaps. More specifically, each pair of base side wall flaps depends from an edge of a base side wall of the pack. Even more specifically, a first base side wall flap of each pair of base side wall flaps depends directly from an edge of a base side wall and a second base side wall flap of each pair depends from the other base side wall flap of the same pair. In this way, each base side wall assembly will comprise two pairs of base side wall flaps depending from opposing edges of a base side wall.

Preferably, the second base side wall flap of each pair of base side wall flaps depends from the first base side wall flap of a pair along a diagonal hinge line between diagonally opposed vertices of the connected pair of base side wall flaps.

During assembly of the pack of the invention, the first, second, third and fourth pairs of base side wall flaps are folded about their respective hinge lines so as to lie on the inner surface of the base portion front and rear panels. In the assembled base portion, the base portion rear and front panels oppose one another and the base portion side walls oppose one another. The base side wall flaps are located at each corner of the assembled base portion, one pair of base side wall flaps at each corner.

In embodiments of the pack wherein a pair of base side wall flaps comprises a diagonal hinge line between diagonally opposed vertices of the connected pair of base side wall flaps, one of the pair depends from an edge of a base portion side wall and the other of the pair from the diagonal hinge line. During assembly, the base side wall flaps are folded about a hinge line connecting same to the edge of the base side wall inward of the base portion and one of the pair is attached to either the base portion rear panel or the base portion front panel. The pair of base portion side wall flaps is folded about the diagonal hinge line which, in turn, raises the base portion rear and/or front panels into position.

In embodiments of the invention, one of the pair of base portion side wall flaps is attached to either the base portion rear panel or the base portion front panel by a releasable mounting. More specifically, the releasable mounting may be a hook and eye fastening, a non-permanent adhesive, or the like. In alternative embodiments, the attachment is by permanent mounting such as permanent adhesive or the like.

The opposing base portion side walls are preferably hingedly attached to the base portion bottom panel. More specifically, the opposing base portion side walls are hingedly attached to, or proximate to, opposing side edges of the base portion bottom panel. When hingedly attached proximate to opposing side edges of the base portion bottom panel, the attachment is to the inner face of the base portion bottom panel.

In certain embodiments, the pack further comprises a second lid portion top panel. More specifically, the second lid portion top panel is hingedly connected to the base portion front panel. In these embodiments, the first and second lid portion top panels will abut one another in the assembled pack. In this way, the assembled pack has a split lid arrangement formed of two separate panels.

In particularly preferred configurations of the present invention, the lid and base portion panels are aligned as follows: lid portion side panel hingedly connected to lid portion top panel which is further hingedly connected to base portion rear panel which is further hingedly connected to base portion bottom panel which is further hingedly connected to base portion front panel.

In various embodiments, the base portion front panel may further be hingedly connected to a base portion inner front panel. In these embodiments, in the assembled pack, the base portion inner front panel lies over the base portion front panel at an inner surface thereof. In this way, the base portion inner front panel reinforces the front panel of the pack thereby giving further strength to the assembled pack.

In embodiments of the invention, the lid and the base portion panels share a common longitudinal axis in the collapsed (flat) pack. In embodiments of the invention wherein the pack comprises a cover layer, the base portion inner front panel may be commonly share the cover layer or, alternatively, may have a further cover layer of its own.

In certain embodiments, the inner flap portion panels are connected to one another along a hinge line. The inner flap portion rear panel and the inner flap portion bottom panel may be hingedly connected to one another along a common fold line formed in the material of the pack. More specifically, the inner lap portion rear panel and the inner flap portion bottom panel may be attached to one another along a hinge line. In alternative embodiments, the inner lap portion rear panel and the inner flap portion bottom panel may be covered by an inner flap cover layer. In this way, the inner lap portion rear panel and the inner flap portion bottom panel are hingedly connected to one another by the inner flap cover layer along a hinge line formed by the inner flap cover layer where the two separate panels abut one another.

It is preferred that the inner flap rear portion has substantially the same dimensions as the base portion rear panel and that the inner flap portion bottom panel and the base portion bottom panel are substantially the same dimensions. In this way, the inner flap serves to cover the hinge lines of the base portion of the pack, thereby providing a neat and high-quality product finish.

In preferred embodiments, the lid portion, base portion and incorporated inner flap portion are joined together as one piece, preferably by at least one cover layer.

Due to its rigid construction, during assembly of the pack from its fully collapsed position, the base portion of the pack is maintained in an erect set-up position. This allows the pack and lid to be re-used and re-folded, it frees the hands of the end-user, the quick assembly without glue or other adhesives means minimal time or effort is required for assembly or disassembly by the end user.

The rigidity of the pack construction allows the base portion of the box to be erected into a set-up position, whether or not the lid portion is in a closed or open position, whilst at the same time hiding the internal mechanism of the base of the pack by virtue of the inner flap portion. This provides a presentable and practical solution, and the pack is designed to minimise the amount of raw edges showing on the main faces as the folding panels cover the internal mechanism.

When used herein, the terms top, bottom, rear, front, side or the like, are not intended to define or to imply any specific orientation of the pack, rather the terms are used to assist the skilled artisan in their understanding of the present invention.

In the fully assembled position of the pack, it is preferred that the base and lid portions together form a parallelepiped box.

In embodiments of the invention, during assembly and also when the pack is fully assembled, the rear panel of the inner flap portion lies on the rear panel of the base portion and the inner flap portion bottom panel lies on the base bottom panel. In this way, the base portion is reinforced in strength when the inner flap portion is in position.

It is preferred that, in the collapsed (flat) position of the pack, the inner flap portion rear panel and bottom panel (if present) lie on the lid portion of the pack. In this way, the flat-pack orientation of the collapsible pack has a compact footprint which is easy and convenient to transport and is protected from damage occurring to the inner flap portion because of same lying within the footprint of the lid and base portion in the collapsed position of the pack.

In embodiments of the present invention, the panels of the base portion and the panels of the lid portion are each and all separate from one another.

In alternative embodiments, some or all of the panels of the base portion and/or some or all of the panels of the lid portion may be connected to one another. More specifically, one or more panels of the pack may be connected to one another along hinge lines.

In further alternative embodiments, some or all of the panels of the base portion and lid portion may be formed integrally with one another. More specifically, the panels may be integral with one another and delimited from one another by fold lines. The fold line may be creased, scored, perforated or otherwise defined in order to be hinge lines in the pack of the present invention.

In certain embodiments, the collapsible pack further comprises at least one cover layer.

It is preferred that the at least one cover layer is a flexible material. More specifically, the cover layer is a flexible paper-based material. In certain embodiments, the cover layer is a flexible laminated paper-based material.

It is further preferred that the at least one cover layer has an adhesive coating applied to one surface thereof. In this way, the cover layer can be adhered to one or more of the panels/walls/flaps of the pack.

In preferred embodiments, the at least one cover layer provides the hinge connections between adjacent panels/walls/flaps. In this way, the panels/walls/flaps of the pack may be repeatedly hinged with respect to one another thereby allowing the pack to be collapsed and assembled as required.

Preferably, the one or more of the panels of the base portion and the panels of the lid portion are connected by the cover layer. More specifically, the base portion bottom, front and rear panels, and the lid portion top panel, at least, are covered by the at least one cover layer. The connection lines between the panels provided by the cover layer form hinge lines between adjacent panels.

In embodiments of the invention, the inner flap portion further comprises a second cover layer. More specifically, the outer surface of the inner flap portion rear panel and, where present, the inner flap portion top panel, are covered by the second cover layer.

In embodiments of the invention, the inner flap portion rear panel is hingedly connected to the base portion rear panel by the second cover layer.

When the inner flap portion comprises a top panel, the second cover layer provides the hinged connection between the inner flap portion rear and top panels.

Where present, the first cover layer covers the external surface of the panels to which it is applied.

In embodiments of the invention, each panel is covered at least one cover layer. More specifically, each panel is covered on its outer and its inner surface by at least one cover layer. In this way, each panel is increased in strength by the presence of one or more covering layers applied to at least one of its surfaces. The cover layer(s) also serves to connect one or more of the panels of the pack together thereby forming a hingeable connection between adjacent panels.

The pack of the present invention can also be flat packed, saving valuable space in retail, home, business and logistics environments. The flat packed feature also requires less packaging for transportation (fewer export cartons) and is more secure for transportation—as ready-assembled boxes are more likely to be damaged in transit.

In embodiments of the invention, the pack may further comprise an insert. More specifically, the insert may be formed by an extension to or, as an additional panel attached to, one or more of the panels or walls of the pack. In certain embodiments, the insert is integrally formed with one or more of the panels of the pack. Alternatively, the insert may be hingedly connected to one or more of the panels of the pack.

In embodiments of the invention, the inner flap portion may be modified to provide an integrated insert for a contents or product(s) to be contained in the erect pack.

In further embodiments, one or both of the base side walls may comprise at least one additional panel forming an insert.

Alternatively, or in addition, the pack may further comprise a removable insert.

The insert of the pack may be configured to retain and/or support a product to be contained in the pack.

In embodiments of the invention, the pack comprises a closure member. The closure member is configured to maintain the pack in the closed position. The closure member may be a magnet and metallic element or, alternatively or in addition, may comprise a ribbon or string-like member.

The pack may comprise one or more carrying handles.

The pack may further comprise a window in a side wall thereof. Alternatively, or in addition, the pack may comprise a window in a lid and/or a base panel thereof.

According to a second aspect, the present invention provides a blank assembly erectable into a collapsible pack, the blank assembly comprising an outer blank having first and second major panels interconnected along hinge lines by a first minor panel and further having a second minor panel depending from the first major panel along a further hinge line; a first inner blank comprising a first minor panel; and a second and a third inner blank each comprising a first major panel and a first and a second minor panel depending from opposing edges of the major panel.

The outer blank may further comprise a third minor panel depending from the second major panel.

The outer blank may further comprise a fourth minor panel depending from the second minor panel along a further hinge line.

The outer blank may further comprise a fifth minor panel depending from the outer blank second minor panel along a further hinge line. In embodiments comprising both a fourth and a fifth minor panel, each depending from the second minor panel, it is preferred that the fifth minor panel depends from an edge of the second minor panel and that the fourth minor panel depends from the inner surface of the second minor panel proximate the edge thereof.

In embodiments of the invention, the inner blank further comprises a first major panel depending from the first minor panel of the inner blank along a hinge line.

In preferred embodiments, the first and second minor panels of the second and third inner blanks each comprise a diagonal fold line between diagonally opposing corners of the panels.

In embodiments of the pack and the blank assembly of the present invention, the panels, flaps and walls are formed of a rigid material. More specifically the rigid material may be a rigid cartonboard material. The rigid material provides strength to the pack and provides protection against crush forces for the contents of the assembled pack. The rigid material also allows the pack to be repeatedly collapsed and assembled for multiple re-use thereof.

The blank assembly according to the second aspect of the invention may be assembled into the collapsible pack of the first aspect of the invention.

More specifically, the major and minor panels of the blank assembly are folded about respective hinge lines to form the collapsible pack of the invention.

In embodiments of the invention, the major and minor panels of the blank assembly correspond to the panels, walls and flaps of the collapsible pack as shown in Table 1 below:—

TABLE 1 Corresponding Blank Assembly Collapsible Pack Feature Feature Base portion front panel Outer blank second minor panel Base portion bottom panel Outer blank first major panel Base portion rear panel Outer blank first minor panel Base portion inner front panel Outer blank fourth minor panel Lid portion top panel Outer blank second major panel Second lid portion top panel Outer blank fifth minor panel Lid portion side panel Outer blank third minor panel Inner flap portion rear panel Inner blank first minor panel Inner flap portion bottom panel Inner blank first major panel First base portion side wall Second inner blank first major panel Second base portion side wall Third inner blank first major panel First pair base portion side wall Second inner blank first minor panel flaps Second pair base portion wall side Second inner blank second minor panel Third pair base side wall flaps Third inner blank first minor panel Fourth pair base portion side wall Third inner blank second minor flaps panel Inner flap portion second rear Inner blank second minor panel panel Inner flap portion connecting strip Inner blank third minor panel Inner flap portion second rear Second inner blank third minor panel panel Inner flap portion connecting panel Inner blank third minor panel Base portion inner bottom panel Outer blank sixth minor panel Base portion inner firs side wall Second inner blank third minor panel Retaining element top panel Third inner blank third minor panel Retaining element side panel Third inner blank fourth minor panel Retaining element bottom panel Third inner blank fifth minor panel

The invention will now be described, by way of example only, with reference to the accompanying drawings, in which:—

FIG. 1 shows a perspective view of a partially assembled collapsible pack according to an embodiment of the first aspect of the present invention;

FIGS. 2 to 8 shows a blank assembly formable into the pack of FIG. 1 during various stages of formation;

FIGS. 9 to 13 shows a perspective view of the collapsible pack of FIG. 1 at various stages of assembly;

FIG. 14 shows a perspective view of a partially assembled collapsible pack according to a first alternative embodiment of the first aspect of the present invention;

FIGS. 15, 16 a and 16 b show the pack of FIG. 14 at various stages of assembly;

FIGS. 17 to 22 show a perspective view of a collapsible pack according to a second alternative embodiment of the invention at various stages of assembly;

FIG. 23 shows a variation of the embodiment depicted in FIGS. 19 to 22;

FIG. 24 shows a blank assembly formable into the pack of FIGS. 17 to 22;

FIGS. 25 to 28 show a perspective view of a collapsible pack according to a third alternative embodiment of the invention at various stages of assembly;

FIG. 29 shows a blank assembly formable into the pack of FIGS. 25 to 28;

FIG. 30 shows a partial cross-sectional representation of the pack of FIG. 27;

FIGS. 31 to 33 show a perspective view of a collapsible pack according to a fourth alternative embodiment of the invention at various stages of assembly;

FIG. 34 shows a blank assembly formable into the pack of FIGS. 31 to 33;

FIGS. 35 to 38 show a perspective view of a collapsible pack according to a fifth alternative embodiment of the invention at various stages of assembly;

FIG. 39 shows a blank assembly formable into the pack of FIGS. 35 to 38;

FIG. 40 shows a partial cross-sectional representation of the pack of FIG. 38;

FIGS. 41 to 43 show a perspective view of a collapsible pack according to a sixth alternative embodiment of the invention at various stages of assembly;

FIG. 44 shows a blank assembly formable into the pack of FIGS. 41 to 43;

FIG. 45 shows a cross-sectional representation of the pack of the sixth alternative embodiment in its fully assembled state;

FIGS. 46 to 48 show a perspective view of a collapsible pack according to a seventh alternative embodiment of the invention at various stages of assembly;

FIG. 49 shows a blank assembly formable into the pack of FIGS. 46 to 48;

FIG. 50 shows a partial cross-sectional representation of the pack of FIG. 48;

FIGS. 51 to 55 show a perspective view of a collapsible pack according to an eighth alternative embodiment of the invention at various stages of assembly;

FIG. 56 shows a blank assembly formable into the pack of FIGS. 51 to 55;

FIGS. 57 to 60 show a perspective view of a collapsible pack according to a ninth alternative embodiment of the invention at various stages of assembly;

FIGS. 61 to 63 show a perspective view of a collapsible pack according to a tenth alternative embodiment of the invention at various stages of assembly;

FIG. 64 shows a blank assembly formable into the pack of FIGS. 61 to 63; and

FIGS. 65 to 74 show perspective views of a collapsible pack according to a various alternative embodiments of the invention in the fully assembled position.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

Further, although the invention will be described in terms of specific embodiments, it will be understood that various elements of the specific embodiments of the invention will be applicable to all embodiments disclosed herein.

In the drawings, similar features are denoted by the same reference signs throughout.

Referring to the figures, FIG. 1 depicts an embodiment of a partially assembled collapsible pack according to an embodiment of the first aspect of the present invention.

FIG. 1 shows one example of the pack, in a partially folded state. In this example, the collapsible pack consists of Panel A, made up of A1, A2, A3 which for the base portion of the pack and panels A4 and A5 which, in this example, form the lid portion, Panel B (B1 and B2 which form, the inner flap portion), Panel C, being panel C1 which is also an inwardly folding panel, Panels D (D1, D2, D3, D4, D5) and E (E1, E2, E3, E4, and E5) which form the side walls and associated side wall flaps.

The collapsible pack has a base portion and a lid portion, together with an inner flap portion B. The base portion itself comprises a front panel A1, a bottom panel A2 and a rear panel A3 each hingedly connected to the adjacent panel along a hinge/fold line. Side walls D3 and E3 complete the main walls and panels of the base portion and are connected along respective fold/hinge lines to the bottom panel A2. Side walls D3 and E3 each have a pair of side wall flaps D1/D2, D4/D5, and E1/E2, E4/E5 respectively, depending from opposing edges thereof. One of each pair of side wall flaps D2, D4, E2, E4 depend directly from an edge of the side wall D3, E3. The second flap of each pair D1, D5, E1, E5 depend along a diagonal hinge line from the other flap of the same pair D2, D4, E2, E4. Side flaps D1 and E1 are each adhered to the front panel A1 of the base portion and side flaps D5 and E5 are each adhered to the rear panel A3 of the base portion. In the depicted embodiment, the base portion further comprises an inner front panel C1, depending from a free edge of the front panel A1 along a hinge line.

The lid portion comprises a top panel A4 connected to the base portion at an edge of the rear panel A3 along a hinge line. In the depicted embodiment, the lid portion further comprises a side panel A5 depending from the free edge of the lid top panel along a further hinge line.

The inner flap portion B comprises a rear panel B1 hingedly connected to the base portion rear panel A3. In the depicted embodiment, the inner flap portion also has a bottom panel B2 connected to the free edge of rear panel B1 along an interconnecting hinge line. Bottom panel B2 has a lifting tag X2 attached to a free edge of the panel B2 to facilitate its lifting from the bottom of the fully assembled pack.

FIG. 1 shows the grey board panels which make up the body of the pack. The panels are A1, A2, A3, A4, and A5. Panels A1, A2, A3 will eventually form part of the base portion, and panels A4 and A5 will eventually form the lid of the pack.

FIG. 1 shows covering layer X1, in the form of a piece of paper, glued to the back side of the five “A” grey board panels. There are small gaps in between the grey board panels to allow flexibility of movement of the panels that make up the pack. The paper is of a thin material such that it bends with the movement of the boards, but is strong enough to hold them in place during movement of the panels. Thus, there are five panels of grey board which are held in place by covering material X1, but their movement is flexible, due to the nature of the gaps between the panels and the covering layer material adhered to them.

Referring to FIG. 2, a first cover layer X1 is adhered to the outer surface of each of panels A1, A2, A4, A4 and A5. The panels A1, A2, A4, A4 and A5 are each separately formed of a rigid cartonboard material. The panels abut one another at hinge lines, with the hinges being formed by the first cover layer X1. A second cover layer X3 is applied to the inner surface of lid top panel A4 and lid side panel A5. The second cover layer X3 partially covers the inner surface of base portion rear panel A3. The second cover layer X3 thus forms a further the hinge line between the lid top panel A4 and the lid side panel A5 and also between the lid top panel A4 and the base portion rear panel A3.

FIG. 2 depicts the edges of the paper covering layer X1 attached to back of boards A1, A2, A3, A4, A5 is then folded over the edges of the panels to securely hold these panels in place. A further sheet of paper X3 is then glued onto the inside face of panels A4 and A5. This additional covering layer hides the material of the grey board and also acts to reinforce the structure of the pack.

As with any component in the pack, the covering layer(s) can be printed with graphics and/or indicia, decorated or coloured. In this way, the covering layer serves to enhance the aesthetic features of the final pack.

Referring to FIGS. 3, 4 and 5, separate inner flap portion rear panel B1 and bottom panel B2 are, together, covered at their outer surface by a further cover layer X4 and at their inner surface by a yet further cover layer (not shown). The cover layer X4 is larger in all dimensions that the panels B1 and B2 and is folded over the edges of the panels at three edges. Joining panel Z1 of cover layer X4 is left unfolded. Inner flap portion rear panel B1 is then hingedly connected to the base portion rear panel A3 by adhering joining panel Z1 of cover layer X4 to the base portion rear panel A3.

In much the same way, base portion inner front panel C1 is covered by cover layer X5, leaving joining panel Z2 to be adhered to the inner surface of base portion front panel A1, thus formed a hinged connection between the two panels proximate the free edge of the base portion front panel A1.

Also in much the same way, side walls D3 and E3 and their respective side wall flaps D1, D2, D3, D4 and E1, E2, E3, E4 are covered by further cover layers X6 and X7 leaving joining panels Z3 and Z4 to be adhered to the inner surface of the base portion bottom panel A2 thereby forming a hinged connection between the side walls and the bottom panel at opposing edges thereof. Joining panels Z3 and Z4 do not extend to the side wall flaps D1, D2, D3, D4 and E1, E2, E3, E4. The side wall flaps are hinged only to their respective side wall panel edges.

As depicted in FIG. 6, a further cover layer X8 is adhered to the inner surface of joining panel Z1, base portion rear panel A3, base portion bottom panel A2, joining panels Z3 and Z4, base portion front panel A1 and joining panel Z2. In this way, cover layer X8 covers and secures all of the joining points and hinge lines of the base portion of the pack. This cover layer X8 hides all the internal mechanism of the pack, leaving a clean and tidy, high-quality internal finish.

As depicted in FIG. 9, side wall flaps D1 and E1 are adhered to the base portion front panel A1 and side wall flaps D5 and E5 are adhered to the base portion rear panel A3. This step completes the assembly of the blank assembly of the depicted embodiment and the collapsible pack is ready for assembly. The dimensions of the inner flap panels B1 and B2 and their hinged connection to the base portion rear panel A3 provide a compact footprint for the collapsed pack reducing the volume of pack for transportation.

FIG. 10 depicted the collapsible pack in a partially assembled position. Each pair of side wall flaps D1/D2, D4/D5, E1/E2 and E4/E5 are folded about the diagonal hinge line between the two flaps in each pair. This causes the side wall flaps of each pair to lie one over the other and raises the base portion rear and front panels A3 and A1 into their erect position. Base portion inner front panel C1 is hinged about the hinge line connecting same to the base portion front panel A1 to cover the inner surface of the base portion front panel A1 with panel C1. Inner flap rear panel B1 is folded onto the inner surface of base portion rear panel A3 and inner flap bottom portion B2 is folded over to cover base portion bottom panel A2 (FIGS. 11 and 12). Finally, the lid panels A4 and A5 are folded so as to close the pack as depicted in FIG. 13.

Panels C1, B1 and B2 each provide inner reinforcing panels for the assembled pack giving additional strength thereto.

FIG. 7 depicts the pack in the fully collapsed position and an additional space reduced stowage position (FIG. 8).

In all of the depicted embodiments, grey board (a rigid paper based material) is used for the panels, and paper as the flexible covering layer material, to form a rigid, paper-wrapped, re-foldable one piece collapsible pack and lid. In this example, paper is used as the interconnecting cover layer material. In alternative embodiments, the panels can be made flexible and foldable through the use of materials that have been pre-cut, pre-creased, pre-folded, or by connecting the panels with a flexible material, which may be a thicker or thinner substrate, or may connect the panels along their entire edges to each other or along part of their abutting edges.

In the embodiment depicted in FIGS. 1 to 13, the inner flap portion B is made up of 2 panels, namely a rear and a bottom panel. Additional embodiments will be described in detail hereinafter, in which the number of panels making up the inner flap portion B is either 1 or more panels. The use of 1 or more panels to make up the inner flap portion gives rise to alternative ways of holding the pack in an erect set up position during assembly. Some of the different variations of the invention will be described in detail herein. Other examples, including constructions where an insert is incorporated into the panels making up the box, will also be described in detail hereinafter.

FIG. 2 shows the inner flap portion B which, in this example, is formed of 2 panels, B1 and B2, which are also made from grey board. A sheet of paper X3 is laminated to the back surface of the grey board panels B1 and B2 such that it holds the pieces in position with a gap between the 2 boards. The gap is sufficient to allow the panels to bend and fold. It will be understood that this same effect may be achieved by other methods, for example, by pre-creasing the material at the join line between the panels to allow bending. In these alternative embodiments, the panels B1 and B2 may be integrally formed.

The cover sheet of paper X3 that is laminated to the back of the two grey board panels is larger than the grey board panels, such that three of the edges of the paper layer X3 can be wrapped over the edge of the grey board as shown in FIG. 3, to secure them more firmly. The fourth edge is left unfolded, i.e. not wrapped over the top surface of panels B1 and B2, thereby forming joining panel Z1.

A separate covering sheet of paper (not shown) is then affixed to the other surface of the panels B1 and B2. One edge of the paper protrudes from the outline of the panels B1 and B2 so that it lies over the fourth edge of the bottom paper X3. These two sheets of paper can then be glued together. These panels B1 and B2 and the two paper sheets together form the integral panel, which is key to the function and assembly of the pack.

FIGS. 3 and 4 show how the inner flap portion is then attached to the body of the pack, by gluing the excess flap of paper forming joining panel Z1 to the inner surface of the base portion rear panel A3, during construction.

Panel C1 is also formed by wrapping a cover layer X5 of paper on the underside and on to the top surface of a piece of grey board. The construction is also such that a piece of excess paper protrudes from one edge of C1 to form joining panel Z2. The panel C1 is shown in FIG. 4, which illustrates C1 being attached to panel A1. This is done by gluing the excess paper flap on C1 to the inner surface of A1, such that there is a small gap between panel C1 and the surface of A1 connected by flexible material (in this example paper) forming joining panel Z1.

Panel C1 in the depicted embodiment is constructed of 1 panel piece only, however, this can be altered in size or structure and additional panels or parts may be added.

The next stage in the construction of the pack from the blank assembly is to add the side panels, as shown in FIG. 5. In the depicted embodiment, the side panels are each constructed of five pieces of grey board. Panel D is made up of D1, D2, D3, D4 and D5. Side wall flap D4 is made of a thicker grey board, to give it more stiffness, and panels D1, D2, D4 and D5 are made of a thinner grey board which eases the folding and unfolding of the pack. Panel E is made up of E1, E2, E3, E4 and E5. Side wall flap E4 is made of a thicker grey board, to give it more stiffness, and panels E1, E2, E4 and E5 are made of a thinner grey board. Panels D and E are wrapped in paper on their front and back surfaces, such that there is a piece of excess paper on one edge of D3 and E3, forming joining panels Z4 and Z3 respectively.

The side panels are then attached to the body of the pack by gluing the excess flaps of paper forming joining panels Z4 and Z3 to the inner surface of panel A2, as shown in FIG. 5. A covering layer of paper X8, as shown in FIG. 6, is then glued to the inner surface of panel A2, so that it covers the inner surface of A1, A2 and A3 and so that this paper also overlaps the excess flaps of paper forming joining panels Z4 and Z3 that have been glued onto the surface of A2, to hold panels C1, B, D and E to the body of the pack. This is further illustrated in FIG. 6, which shows how the cover layer of paper X8 overlaps the joining panels of paper holding C1 and B1 to the body of the pack. This arrangement has the effect of reinforcing the bond between the various panels.

Panels D1 and D5, E1 and E5 are then glued to the top surface of the paper cover layer X8 that lines the inner surfaces of the pack, in this example, as illustrated in FIG. 6. The edge of D1, D3 and D5 and correspondingly the edge of E1, E3, and E5 are joined respectively to each side of the panels A1, A2 and A3, and all the Panels D and E lie flat against the surface of A1, A2 and A3 when the box is in a flat position. There are alternative constructions, in which panels D1 and D5, E1 and E5 do not all need to be glued, and these will be explained and illustrated hereinafter.

FIG. 9 illustrates the completed collapsible pack as described in this embodiment. The pack can be further flat packed for transportation and storage as depicted in FIGS. 7 and 8.

Folding and Assembly

The following steps as depicted in FIGS. 9 to 13, describe how the pack in the above embodiment can be folded and unfolded by the user.

The positions of the panels and the flexible joins between the individual panels making up the main parts of the collapsible pack are such that the pack can be folded into a setup position and easily disassembled into a flat pack position. In the depicted embodiment, the paper covering layer interconnecting material that wraps the grey board, is flexible, thus allowing movement at the joins and the panels to fold. The hinge line between D3 and A2 and, correspondingly the hinge line between E3 and A2, are flexible so that D3 and E3 can lie flat against the surface of A2 or fold upwards to a position at 90 degrees to the surface of A2. Similarly, the hinge line between panels C1 and A1 is flexible, as is the hinge line between the inner flap portion B and panel A. The hinge line between panels making up the body of the pack, A, namely A1, A2, A3, A4, A5, are also flexible, as are the panels making up the side panels D and E, with the exception of D1 and D5, E1 and E5 are they are glued to the inside surfaces of panels A1 and A3, in this example.

The process of folding the collapsible pack into a set-up position is illustrated in FIG. 9 through to FIG. 13. The process can be reversed to unfold the pack back to a flat/collapsed pack position. Lifting tags (X2) such as ribbons, or the like, may be added to the edge of panel B2 and/or panel C1 to make unfolding even simpler as they provide an area that can easily be gripped by the user to unfold the panels; an exemplary ribbon X2 is illustrated in FIG. 10 to FIG. 12 attached to B2. Alternative solutions for gripping the edge of the panels could also be used, an example of which are small cuts or finger holes.

To assemble the pack from a flat/collapsed position, A1 and A3 are pushed towards each other by the end user either by holding onto the Lid (A4/A5) and inner front panel C1, or at some other location such that A1 and A3 lie at 90 degrees against the surface of the inner face of panel A2.

This motion will automatically fold D3 and E3 into a vertical (90 degree) position against the inner surface of A2, if the panels D1, D5, E1 and E5 have been affixed to A1 and A3 respectively as described in this example, otherwise the user will need to push these side panels in. The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the pack. Due to the folding up of panels D3 and D4, the panels D1 and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such that their surfaces lie flat against each other, this processes is illustrated in FIG. 11, where D4 and D5, E4 and E5 are pushed towards each other as the box is set up.

Panel C1 is then folded over such that its inner surface lies flat against the inner surface of panel A1, as illustrated in FIG. 10. The panel C1, in its folded position, will cover the panels D1 and D2, E1 and E2, so that they lie underneath panel C1 between C1 and A1.

An integral feature of this flat packing, quick-fold erect, re-foldable one piece box & lid, the incorporated Panel B, is then folded over such that the inner surface of panel B1 lies flat against A3, as shown in FIG. 11 and FIG. 12. The panel B1, in its folded position, will cover the panels D4 and D5, E4 and E5, so that they lie underneath panel B1 between B1 and A3.

The Panel B2, is then be pushed down so that it lies flat against the panel A2. The length of the panels in this example are such that the base of panel C1 rests just above the base of the box, the length of panel B2 is such that the end of panel B2 pushes against C1. In this way, the pushing down of panel B2, or an incorporated panel added for this purpose, has the effect of holding panel C1 and B1 in place in their folded positions, hence holding the base of the box in a set up position. Thus, the base of the pack is now erected with A1, A3, D3 and E3 all at 90 degrees to the inner surface of A2 and held in place by the folding of the inner panels B and also C1 as described above. With the panels in this position, the bottom part of the box will remain erected whether or not the lid, comprised of A4 and A5, is opened or closed. This arrangement of panels making up B (in this example B1 and B2) and the folding of these panels is one of several variations of the invention demonstrating how the inner flap portion panel (or panels) holds the base of the box in an erect set-up position. There are alternative ways to hold the base of the box in a set up position, using an incorporated panel (or panels) without the panel B2 resting against the base of the box, or against C1, and examples of this will be described and illustrated hereinafter.

The panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the panel A5 folding over the outer surface of A1, as illustrated by FIG. 13. To keep the lid closed on the box when in an erected position, A5 can be attached to the outer surface of panel A1 through the use of magnets, clips, cuts, additional parts, ribbons, ties or other suitable retaining means.

The pack has advantages over known pack constructions in that the base, lid and incorporated integral inner flap portion can be folded into a flat-packed position. FIG. 7 illustrates a top view of the pack in a flat position. FIG. 8 demonstrates how the panels of the pack may be further folded, to minimise the area the flat packed pack requires. FIG. 7 illustrates the direction in which panel C1 may be folded over. FIG. 8 illustrates how panels B1 and B2 are folded over the inside face of panels A1, A2, A3 and the folded panel C1. FIG. 8 also shows how panels A4 and A5 are folded around the back of the pack. Alternatively, panels A4 and A5 may be folded around the back, and panels B1, B2 and C1 folded over the inside of the box, all in a flat packed position. The folding of the panels reduces the footprint area the collapsed pack takes up, making it easier to store and also more compact for shipping which reduces the risk of damage in transit, as well as saving space.

The following is a description of an alternative embodiment of the construction of a collapsible pack of the invention, described solely by way of example, in which the inner flap portion B is made of one panel. In this example, grey board (a rigid paper based material) is used for the panels, and paper as the flexible connecting material, to form a rigid paper wrapped re-foldable one piece box and lid. In this example, an alternative method of holding the box in an erect set up position shall be described, whereby the panels B and C are held in place by magnets.

FIGS. 14 to 16 b show an alternative example of the construction of a collapsible pack of the invention, made of panels wrapped with a cover layer of paper interconnecting material. This particular embodiment differs from that depicted in FIGS. 1 to 13 in that the incorporated inner flap portion B is formed of one panel, namely inner flap portion rear panel B1.

The collapsible pack depicted in the embodiment is held in the erect position by magnets X11 (FIG. 15). Alternatively, Velcro fasteners may be used. Permanent fixings may be used however it is preferred that the pack may be disassembled and is re-foldable.

FIGS. 16 a and 16 a show how the pack maybe folded into a set up position by the user. In this example, the folding of the incorporated panels is such that B1 and C1 are held in place by magnets X11 (FIG. 15), thus holding the box in a set up position. In this embodiment, the lifting tag X2 is located on inner flap rear panel B1. Although not shown, inner front panel C1 may have a further lifting tag at an edge thereof to assist the user in disassembling the pack.

FIGS. 16 a and 16 b illustrate the assembled pack in an open position with the lid portion A4 and A5 being foldable to close the pack.

Folding and Assembly

The following steps will now describe how the pack of FIGS. 14 to 16 b can be folded and unfolded by the user, thus illustrating how this alternative version of the invention functions.

The process of folding into a set-up can easily be reversed to unfold the boxes back to a flat pack position.

To assemble from a flat position, base portion front panel A1 and rear panel A3 are pushed towards each other by the end user (either by holding onto the Lid (A4/A5) and end panel C1, or some other location) such that A1 and A3 lie at 90 degrees against the surface of the inner face of base portion bottom panel A2, as illustrated by FIG. 15.

This motion will automatically fold side walls D3 and E3 into a vertical (90 degree) position against the inner surface of bottom panel A2. The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the pack.

Inner front panel C1 is then folded over such that its inner surface lies flat against the inner surface of base front panel A1. The inner front panel C1, in its folded position, will cover the side wall flaps D1 and D2, E1 and E2, so that they lie underneath inner front panel C1 between C1 and A1. In this example, C1 is held in place by magnets X11 under the paper surface of panel C1 and by magnets correspondingly on the inside surface panel A1 (not shown).

The inner flap rear panel B1, is then folded over such that the inner surface of panel B1 lies flat against base portion rear panel A3, as shown in FIG. 16 a. The inner flap portion rear panel B1, in its folded position, will cover the panels side wall flaps D4 and D5, E4 and E5, so that they lie underneath panel B1, between B1 and A3. In this example, B1 is held in place by magnets (X11) under the paper surface of panel B1 and by magnets (not shown) correspondingly on the inside surface panel A3.

Thus, the bottom part of the pack is now erected with A1, A3, D3 and E3 all at 90 degrees to the inner surface of A2 and held in place by the folding of the inner panel B1 and also C1 as described above, as illustrated by FIG. 16 a and FIG. 16 b. With the panels in this position, the bottom part of the pack will remain erected whether or not the lid, comprised of lid top panel A4 and lid side panel A5 is opened or closed. The panel lid top panel A4 can be folded over the top of the erected bottom part of the pack to act as a lid or cover, with the lid side panel A5 folding over the outer surface of base portion front panel A1.

FIGS. 17 to 22 show a second alternative embodiment of a collapsible pack according to the invention, described solely by way of example, in which the inner flap portion B is formed of two panels and an additional second lid portion top panel F1 is connected to base portion front panel A1 of the pack. In this example, the pack will open in the centre, as the lid is formed by second lid portion top panel F1 on one side and first lid top panel A4 on the other, as illustrated by FIGS. 21 and 22 in particular. In this example, grey board (a rigid paper based material) is used for the panels, and paper as the flexible cover layer connecting material, to form a rigid paper wrapped re-foldable one piece box and lid.

In the depicted second alternative embodiment of a collapsible pack according to the invention, the panels are wrapped with a paper interconnecting material. In this particular example, the inner flap portion B is formed of two panels, rear panel B1 and bottom panel B2 and the lid portion can be opened in the centre of the pack, through the incorporation of a second lid top panel F1. Thus, the depicted embodiment differs from the embodiment shown in FIGS. 1 to 13 only in that there is an additional top lid panel F1.

FIG. 18 to FIG. 22 show how the pack of the depicted embodiment can be folded into a set up position by the user. In this example, the folding of the incorporated panels is such that inner flap portion bottom panel B2 rests against base portion inner front panel C1 thereby holding the box/base portion in a set up position.

FIG. 22 illustrates the completed, fully assembled pack as described in this example. This can be further flat packed for transportation and storage.

Folding and Assembly

The following steps will now describe how the pack in the above example can be folded and unfolded by the user.

The process of folding into a set-up position is similar to that described in respect of FIGS. 1 to 13. The folding process can easily be reversed to unfold the boxes back to a flat pack position.

To assemble from a flat position, base portion front panel A1 and base portion rear panel A3 are pushed towards each other by the end user, either by holding onto the lid panels (A4/A5) and inner front panel C1, or some other location, such that base portion front panel A1 and base portion rear panel A3 lie at 90 degrees to the surface of the inner face of base portion bottom panel A2, as illustrated in FIGS. 19 and 20.

Base portion inner front panel C1 is then folded over such that its inner surface lies flat against the inner surface of base portion front panel A1. Base portion inner front panel C1, in its folded position, will cover the side wall flaps D1 and D2, E1 and E2, so that they lie underneath panel C1 between C1 and A1.

An integral feature of this flat packing, quick fold erect, re-foldable one piece base and lid, is that the inner flap Panel B, is then folded over such that the inner surface of inner flap portion rear panel B1 lies flat against base portion rear panel A3. The inner flap rear panel B1, in its folded position, will cover the side wall flaps D4 and D5, E4 and E5, so that they lie underneath panel B1 between B1 and A3.

The inner flap portion bottom panel B2, is then be pushed down so that it lies flat against the base portion bottom panel A2 as illustrated in FIGS. 19, 20 and 21. The pushing down of panel B2 or, an incorporated panel added for this purpose, has the effect of holding base portion inner front panel C1 and inner flap portion rear panel B1 in place in their folded positions, hence holding the base of the box in a set up position, as illustrated in FIG. 21. Thus the bottom part of the box is now erected with base portion front panel A1, base portion rear panel A3, first base portion side wall D3 and second base portion side wall E3 all at 90 degrees to the inner surface of base portion bottom panel A2 and held in place by the folding of the inner flap panels B and also base portion inner front panel C1 as described above. With the panels in this position, the bottom part of the box will remain erected whether or not the lid, comprised of first lid portion top panel A4 and second lid portion top panel F1, is opened or closed.

The lid top panels A4 and F1 can then be folded over the top of the erected bottom part of the box to act as a lid or cover, as illustrated in FIGS. 21 and 22. This example shows the lid being held closed through the use of a ribbon tie, which is attached to the box through small holes in the lid panels A4 and F1.

FIG. 23 shows variation of the embodiment shown in FIGS. 19 to 22. In this particular example, the inner flap portion B is made of 1 rear panel B1 only. As with the second alternative embodiment of FIGS. 17 to 22, the lid portion is formed of two top lid panels A4 and F1, thus the lid of the pack opens in the centre. In this particular embodiment, inner front panel C1 and inner flap portion rear panel B1 may be held in place in their erect positions by way of magnet, or the like (not shown), located on the base portion front and rear panels respectively.

FIG. 24 shows a blank assembly formable into the collapsible pack depicted in assembled form in FIGS. 19 to 22. The depicted blank assembly differs from that depicted in FIGS. 2 to 8 in that the outer blank third minor panel A5 is absent and, in its place is outer blank fifth minor panel F1. Furthermore, the outer blank second major panel is reduced in size relative to the full lid sized panel of FIGS. 2 to 8. In the embodiment depicted in FIG. 24, the outer blank second major panel is approximately half the width of the corresponding panel in FIGS. 2 to 8. The blank assembly depicted in FIG. 24 has an outer blank second major panel and an outer blank fifth minor panel of equal width dimension. Panels A4 and F1 will form the lid portion top panels in the collapsible pack formed from the depicted blank assembly.

FIGS. 25 to 28 show a third alternative embodiment of a collapsible pack according to the invention. The associated blank assembly is depicted in FIG. 29. In this example, a product retaining compartment is incorporated into the base portion of the box, and the side wall panels D and E have been modified to provide an integral insert in the pack to hold a product in the top of the box. The box is held in a set up position by the folding of the inner flap panels B and base portion front panels C.

The embodiment is an example of a pack with an integrated fitment or insert and integrated compartment. The number of panels used, cut-outs, panel dimensions and configuration can all be altered to hold a variety of products.

FIG. 29 shows a blank assembly for the collapsible pack depicted in FIGS. 25 to 28 in its flat packed state. In this example, the blank assembly consists of Panel A, made up of outer blank second minor panel A1, outer blank first major panel A2, outer blank first minor panel A3 which, in the collapsible pack, will together form the base of the pack, and outer blank second major panel A4 and outer blank third minor panel A5, which in the collapsible pack will form the lid top panel and lid side panel respectively. Panel B is formed of inner blank first minor panel B1, inner blank first major panel B2, inner blank second minor panel B3 and inner blank third minor panel B4 which form the inner flap portion rear panel, bottom panel, second rear panel and connecting strip respectively in the collapsible pack. Panel C which is also an integral folding panel, made of base inner front panel C1 and second base inner front panel C2.

Panels D and E form the side walls of the collapsible pack as follows:—first pair of base side wall flaps D1/D2, base first side wall D3, second pair of base side wall flaps D4/D5, base inner side wall D6, third pair base side wall flaps E1/E2, second base side wall E3, fourth pair base side wall flaps E4/E5, retaining element top panel E6, retaining element side panel E7, retaining element bottom panel E8/E9.

The panels B, C, D and E in this example fold together to form an integral insert in the form of a retaining element, which will be described in more detail below.

Folding and Assembly

The following steps will now describe how the pack in the above example can be folded and unfolded by the user.

The interconnecting material between the joins of the panels is flexible, allowing movement at the joins, and the panels to fold. The process of folding into a set-up position is illustrated step by step in FIGS. 25 to 28. This process can easily be reversed to unfold the boxes back to a flat pack position.

To assemble from a flat position, base portion front panel A1 and base portion rear panel A3 are pushed towards each other by the user, either by holding onto the panels of the lid (A4/A5) and end panel C, or some other location such that A1 and A3 lie at 90 degrees to the surface of the inner face of panel A2, as illustrated in FIG. 26.

This motion will automatically fold D3 and E3 into a vertical (90 degree) position against the inner surface of A2. The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the box. Due to the folding up of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such that their surface lie flat against each other, as previously explained.

Panel B is folded over, as illustrated in FIG. 26. The panels B1, B2, B3, B4 are folded such that B1 lies against the inside surface of A1 (thus holding D4, D5 and E4, E5 in place). Panels B2 and B4 lie parallel to A2. Panel B4 lies against the inside surface of A2. This forms a ledge, as illustrated by the side view FIG. 30.

Panel C1 is then folded over such that its inner surface lies flat against the inner surface of panel A1, as illustrated in FIG. 30. The panel C1, in its folded position, will cover the panels D1 and D2, E1 and E2, so that they lie underneath panel C1 between C1 and A1, thus holding them in place. C2, is then folded over so that the under surface of the edge of C2 lies against the top surface of the panel B2, thus forming a compartment under C2, and this will hold the box in a set up position. This is illustrated in the cross-sectional view of FIG. 30. This is an alternative method for holding the box in a set up position by the use of integral incorporated panels.

The compartment defined by panels D6, E6, E7, E8 and E9 has a variety of functions and can be used to hold any product or may be left empty. In this example base inner bottom panel C2 has a recess cut in one side edge so that a cable or wire of an electrical product (or any other product) can be fed into the bottom compartment during packing, and the main body of the product held in the top part of the box for display, for example.

Base inner side wall panel D6 is then folded over. In this example, panel D6 has a “U”-shaped recess cut into it to receive an insert Y1 as illustrated in FIGS. 27 and 28. At the opposite side of the box, the retaining element top panel E6, retaining element side panel E7, and retaining element bottom panels E8 and E9 are folded over onto the top surface of the base portion inner bottom panel C2. Together, a recess formed in the retaining element side and bottom panels, and the insert Y1 held in place by base inner side wall D6, can be used to hold the main body of the product in this top compartment of the box. As the base of the box is held in an erect set-up position the lid can be left open, thus allowing the product to be displayed, or closed.

The lid portion top panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the lid portion side panel A5 folding over the outer surface of base portion front panel A1, as illustrated by FIG. 28. In this example a CD holder Y2 is attached to the inner surface of lid portion top panel A4, by way of example.

FIG. 31 to FIG. 34: show a fourth alternative embodiment of a collapsible pack and associated blank assembly of the invention. In the depicted embodiment, an insert is incorporated into the side wall panels D and E to hold a product.

The following is an example of a box with an integrated insert fitment incorporated into the side wall panels of the box.

FIG. 34 shows the box in a flat position with the blank assembly fully formed and flat. In this example the pack consists of Panel A, made up of base portion front panel A1, base portion bottom panel A2, base portion rear panel A3 which form the base of the box and lid portion top panel A4 and lid portion side panel A5 which form the lid of the assembled pack; Panel B, made up of inner flap rear panel B1 and inner flap portion bottom panel B2 which form the integral incorporated folding panel; base portion inner front panel C1 which is also an integral folding panel; Panels D and E (D1, D2, D3, D4, D5, D6, D7, D8 and D9, E1, E2, E3, E4, E5, E6, E7, E8 and E9) which form the side wall panels and flaps as well as the insert elements of the pack. In this example, the extra panels incorporated into the side wall panels D and E fold to form an integral insert fitment, which will be described in more detail below.

Folding and Assembly

The process of folding into a set-up position is illustrated step by step in FIGS. 31 to 33. This process can easily be reversed to unfold the boxes back to a flat pack position.

As with the other collapsible pack described previously, to assemble from a flat position, panels A1 and A3 are pushed towards each other by the end user (either by holding onto the Lid (A4/A5) and end panel C, or some other location) such that A1 and A3 lie at 90 degrees to the surface of the inner face of panel A2, as illustrated by FIG. 31.

This motion will automatically fold side wall panels D3 and E3 into a vertical (90 degree) position against the inner surface of base portion bottom panel A2. The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the box. Due to the folding up of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such that their surface lie flat against each other, this processes is illustrated in FIG. 31, where D4 and D5, E4 and E5 are pushed towards each other as the box is set up.

Base portion inner front panel C1 is then folded over such that its inner surface lies flat against the inner surface of base portion front panel A1, as illustrated in FIG. 31. The panel C1, in its folded position, will cover the panels D1 and D2, E1 and E2, so that they lie underneath panel C1 between C1 and A1.

A feature of this flat packing, quick fold erect, re-foldable one piece box & lid of this embodiment is that the inner flap portion Panel B, is then folded over such that the inner surface of inner flap rear panel B1 lies flat against base portion rear panel A3, as shown in FIG. 32. The panel B1, in its folded position, will cover the panels D4 and D5, E4 and E5, so that they lie underneath panel B1 between B1 and A3.

The inner flap portion bottom panel B2, is then be pushed down so that it lies flat against the base portion bottom panel A2 as illustrated in FIG. 32. The pushing down of panel B2, or an incorporated panel added for this purpose, has the effect of holding panel C1 and B1 in place in their folded positions, hence holding the base of the box in a set up position. Thus, the bottom part of the box is now erected with A1, A3, D3 and E3 all at 90 degrees to the inner surface of A2 and held in place by the folding of the inner panels B and also C1 as described above, as illustrated by FIG. 32. With the panels in this position, the bottom part of the box will remain erected whether or not the lid, comprised of A4 and A5, is opened or closed.

The side wall panels D6, D7, D8 and D9 are then folded to form an insert fitment at one end of the inside of the box. On the opposite side of the box, retaining element panels E6, E7, E8, and E9 are also folded to form an insert fitment. The folding is illustrated by FIG. 32. In this example, the insert fitment is design to hold a bottle, which is held in place by the insert fitment, and displayed when the lid (panels A4 and A5) is open.

The lid portion top panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the lid portion side panel A5 folding over the outer surface of base portion front panel A1, as illustrated by FIG. 33. To keep the lid closed on the box when in an erected position, A5 can be attached to the outer surface of panel A1 through the use of magnets, clips, cuts, additional parts, ribbons, ties or any other suitable means.

FIGS. 35 to 39 show a collapsible pack and associated blank according to a fifth alternative embodiment of the invention. In this example, an insert fitment has been incorporated into the base portion panel C, and this example shows an alternative way the panels can be configured and folded to hold the box in a set up position.

The following is an alternative example of a box with an integrated fitment incorporated into the panels of the box.

FIG. 39 shows the fully assembled blank assembly for the collapsible pack of this embodiment in a flat state. The collapsible pack formed from the blank assembly of FIG. 39 comprises Panel A, made up of base portion front panel A1, bottom panel A2, and rear panel A3 which form the base of the box and lid portion top panel A4 and side panel A5 which in this example form the lid of the pack; Panel B, formed of inner flap portion rear panel B1, bottom panel B2, second rear panel B3 and connecting strip B4 which form the integral inner flap folding panel; Panel C which is also an integral folding panel, made of base portion inner front panel C1, inner bottom panel C2, inner bottom connecting flap C3, second inner bottom panel C4, retaining flaps C5, C6, C7, C8, C9, C10, and C11; Panels D and E (D1, D2, D3, D4, D5, E1, E2, E3, E4, E5) which form the side walls and flaps. In this example, the extra panels incorporated into the panels B and C fold to form an integral insert fitment, which will be described in more detail below.

Folding and Assembly

The process of folding into a set-up position is illustrated step by step in FIGS. 35 to 38. This process can easily be reversed to unfold the boxes back to a flat pack position.

The base portion of the pack is assembled in the same way as described in respect of previous embodiments.

Panel B is folded over, as illustrated in FIG. 35 and FIG. 36. The panels B1, B2, B3, and B4 are folded such that B1 lies against the inside surface of A1 (thus holding D4, D5 and E4, E5 in place). Panels B2 and B4 lie parallel to A2. Panel B4 lies against the inside surface of A2. This forms a ledge, as illustrated by the side view FIG. 40.

Panel C1 is then folded over such that its inner surface lies flat against the inner surface of panel A1, as illustrated in FIG. 36. The panel C1, in its folded position, will cover the panels D1 and D2, E1 and E2, so that they lie underneath panel C1 between C1 and A1, thus holding them in place. C2, which is attached to C1, is then folded over so that the under surface of the edge of C2 lies against the top of B2.

The panels C2 and C4 have a number of slots cut out of them to hold products. In this example, C2 has 3 slots to hold 3 bottles. To hold the bottles more securely, the panel C2 has small retaining panels (C6, C7, C8, C9, C10 and C11) attached to each side of the 3 bottle slots, as illustrated in FIG. 37. FIG. 37 shows a bottle being placed into the assembled insert fitment. Panel C4 is then folded over the top of the products to hold them in place.

The lid top panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the lid side panel A5 folding over the outer surface of base front panel A1. To keep the lid closed on the box when in an erected position, A5 can be attached to the outer surface of panel A1 through the use of magnets, clips, cuts, additional parts, ribbons, ties or other method.

FIGS. 41 to 45 depicted a sixth alternative embodiment and associate blank assembly of the invention. FIG. 45, in particular, depicts a partial cross-sectional representation of the pack of the sixth alternative embodiment.

In this example, an alternative insert fitment has been incorporated into the inner flap portion panels B, and this example shows an alternative way the integral incorporated panels can fold to hold the box in a set up position.

The sixth alternative embodiment is an example of a box, which in its fully assembled form is a cube shaped pack, with an integrated insert fitment. This example also describes an alternative construction, in that side wall flaps D1 and D5 are not attached to the inside surface of base portion front and rear panels A1 and A3 respectively.

FIG. 44 shows the box in a flat/collapsed state following formation of the associated blank assembly. In this example the box consists of Panel A made up of base portion front panel A1, base portion bottom panel A2, base portion rear panel A3 which form the base of the box, and lid top panel A4 and lid side panel A5 which, in this example, form the lid of the pack; Panel B made up of inner flap portion rear panel B1 and inner flap portion bottom panel B2 which form the integral inner flap folding panel; Panel C which is also an integral folding panel, made of base portion inner front panel C1, base portion inner bottom panel C2, base portion inner bottom connecting panel C3, and second base inner bottom panel C4; base side walls and flaps D and E made up to first pair base side wall flaps D1/D2, first base side wall D3, second pair base side wall flaps D4/D5, third pair base side wall flaps E1/E2, second base side wall E3, fourth pair base side wall flaps E4/E5 which together form the side panels of the pack.

Folding and Assembly

The process of folding into a set-up position is illustrated step by step in FIGS. 41 to 43. This process can easily be reversed to unfold the boxes back to a flat pack position.

To assemble from a flat position, base portion panels A1 and A3 are pushed towards each other by the end user (either by holding onto the Lid (A4/A5) and end panel C, or some other location) such that A1 and A3 lie at 90 degrees to the surface of the inner face of panel A2, as illustrated in FIGS. 41, 42 and 43.

This motion will automatically fold side wall E3 into a vertical (90 degree) position against the inner surface of bottom panel A2. As D1 and D5 are not glued to the inner surface of A2 and A3 respectively, panel D3 will need to be pushed in by the user, so that it is at 90 degrees to the surface of A2, as illustrated by FIG. 41.

The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the box. Due to the folding up of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such that their surface lie flat against each other, this processes is illustrated in FIG. 42, where D4 and D5, E4 and E5 are pushed towards each other as the box is set up.

Then, Panel C is folded over, as illustrated in FIG. 42. The panels C1, C2, C3, and C4 are folded such that C1 lies against the inside surface of A1 (thus holding D4, D5 and E4, E5 in place). Panels C2 and C4 lie parallel to A2. Panel C4 lies against the inside surface of A2. This forms a ledge, as illustrated by the partial cross-sectional view of FIG. 45.

Panel B1 is then folded over such that its inner surface lies flat against the inner surface of panel A3, as illustrated in FIG. 42. The panel B1, in its folded position, will cover the panels D1 and D2, E1 and E2, so that they lie underneath panel B1 between B1 and A3, thus holding them in place. B2, which is attached to B1, is then folded over so that the under surface of the edge of B2 lies against the top of C2.

In this example, panel B2 has a circular hole cut in the centre to hold a candle.

The panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the panel A5 folding over the outer surface of A1, as illustrated by FIG. 45. To keep the lid closed on the box when in an erected position, A5 can be attached to the outer surface of panel A1 through the use of magnets, clips, cuts, additional parts, ribbons, ties or other method.

FIGS. 46 to 49 show a collapsible pack and associated blank assembly of a collapsible pack according to a seventh alternative embodiment of the invention. FIG. 50 shows a partial cross-section representation of the insert of FIG. 48. In this example, a compartment been incorporated into the box.

The following is an alternative example of a box with an integrated internal compartment incorporate into the panels that form the box.

FIG. 49 shows the box in a flat/collapsed state following formation of the associated blank assembly. In this example as in previously described examples, the box consists of Panel A (made up of A1, A2, A3 which for the base of the box and panels A4 and A5 which in this example form the lid), Panel B (B1 and B2) which form the integral incorporated folding panel), Panel C which is also an integral folding panel, made of panel C1. The box further consists of Panels D and E (D1, D2, D3, D4, D5, D6, D7, D8, D9, D10, E1, E2, E3, E4, E5) which form the side wall panels of the pack. Panels D6, D7, D8, D9 and D10 fold to form the internal compartment.

Folding and Assembly

The process of folding into a set-up position is illustrated step by step in FIGS. 46 to 48. This process can easily be reversed to unfold the boxes back to a flat pack position.

As in previous examples, to assemble from a flat position, A1 and A3 are pushed towards each other by the end user (either by holding onto the Lid (A4/A5) and end panel C, or some other location) such that A1 and A3 lie at 90 degrees against the surface of the inner face of panel A2, as illustrated by FIG. 46.

This motion will automatically fold D3 and E3 into a vertical (90 degree) position to the inner surface of A2. The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the box. Due to the folding up of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such that their surface lie flat against each other, this processes is illustrated in FIG. 47, where D4 and D5, E4 and E5 are pushed towards each other as the box is set up.

Panels D6, D7, D8, D9 and D10 are then folded to form a compartment, as illustrated by FIGS. 46 and 47.

Then, Panel C is folded over, as illustrated in FIG. 46, such that C1 lies against the inside surface of A1 (thus holding D4, D5 and E4, E5 in place).

Panel C1, whose width has been adjusted for this purpose, also covers panel D10 and hence holds the internal compartment in place.

Panel B, is then folded over such that the inner surface of panel B1 lies flat against A3, as shown in FIG. 47. The width of panels B1 and B2 is reduced so that they do not overlap the compartment. The panel B1, in its folded position, will cover the panels D4 and D5, E4 and E5, so that they lie underneath panel B1 between B1 and A3. B1 also covers panel D9, hence holding the internal compartment in place.

The Panel B2, is then be pushed down so that it lies flat against the panel A2 as illustrated in FIG. 48. The pushing down of panel B2, or an incorporated panel added for this purpose, has the effect of holding panel C1 and B1 in place in their folded positions, hence holding the base of the box in a set up position. Thus the bottom part of the box is now erected with A1, A3, D3 and E3 all at 90 degrees to the inner surface of A2 and held in place by the folding of the inner panels B and also C1 as described above. With the panels in this position, the bottom part of the box will remain erected whether or not the lid, comprised of A4 and A5 is opened or closed.

The panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the panel A5 folding over the outer surface of A1. The box is now divided, by the incorporated internal panels into a larger and smaller compartment.

FIGS. 51 to 56 show a collapsible pack and associated blank assembly of a collapsible pack according to a eighth alternative embodiment of the invention. In this example, extra panels have been incorporated onto panels B and C and this example demonstrates an alternative configuration of the folding of the incorporated panels to hold the box in a set up position.

The following is an alternative example of a box with incorporated internal panels. This example of the construction of the box is designed to hold a wallet.

FIG. 56 shows the box in a flat/collapsed state following formation of the associated blank assembly. In this example, as in previously described examples, the box consists of Panel A (made up of A1, A2, A3 which for the base of the box and panels A4 and A5 which in this example form the lid), Panel B (B1, B2 and B3) which form the integral incorporated folding panel), Panel C which is also an integral folding panel, made of panels C1 and C2, Panels D and E (D1, D2, D3, D4, D5, E1, E2, E3, E4, E5) which form the side walls and flaps of the pack.

Folding and Assembly

The process of folding into a set-up position is illustrated step by step in FIGS. 51 to 55. This process can easily be reversed to unfold the boxes back to a flat pack position.

To assemble from a flat position, A1 and A3 are pushed towards each other by the end user (either by holding onto the Lid (A4/A5) and end panel C, or some other location) such that A1 and A3 lie at 90 degrees against the surface of the inner face of panel A2, as illustrated in FIG. 51.

This motion will automatically fold D3 and E3 into a vertical (90 degree) position to the inner surface of A2. The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the box. Due to the folding up of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such that their surface lie flat against each other, this processes is illustrated in FIG. 52, where D4 and D5, E4 and E5 are pushed towards each other as the box is set up.

Then, Panel C is folded over, as illustrated in FIG. 52 and FIG. 53, such that C1 lies against the inside surface of A1 (thus holding D4, D5 and E4, E5 in place). Panel C2 is then pushed down so that it lies flat against the panel A2.

Inner flap portion rear panel B1, and inner portion side flaps B2 and B3, which depend from the side edges of rear panel B1, are then folded over. This arrangement would hold the product, in this example, a wallet in place in the box. The surfaces, as with any part of the box, could be printed on to improve the aesthetic appeal of the product, as well as printing text on the surface.

The lid portion top panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the lid portion side panel A5 folding over the outer surface of base front panel A1, as illustrated by FIG. 54. The box is now divided, by the incorporated internal panels into a larger and smaller compartment. Base portion rear panel A3, in this embodiment is covered by lid rear split panel A6 and A7. Panels A6 and A7 are connected along a hinge line positioned half way between the bottom and the top of base portion rear panel A3. This hinge line allows the lid portion of the pack to be hinged completely away from the base portion.

FIGS. 57 to 60 depict a ninth alternative embodiment of a collapsible pack of the invention and how it can be folded into a set up position by the user. In this example, extra panels have been incorporated onto inner flap panel B to form a divider in the box.

The following is an alternative example of a box, with an integrated divider, which forms two separate compartments, to hold a product such as shoes.

FIG. 57 shows the box in a flat state. In this example the box consists of Panel A (made up of A1, A2, A3 which for the base of the box and panels A4 and A5 which in this example form the lid); Panel B made of inner flap portion rear panel B1, inner portion bottom panel B2 and inner flap portion divider panel B3 which form the integral incorporated folding panel; Panel C which is also an integral folding panel, made of base portion front inner panel C1, Panels D and E (D1, D2, D3, D4, D5, E1, E2, E3, E4, E5) which form the side walls and flaps. In this embodiment, inner flap bottom panel B2 is dimensioned to cover only a portion of the base portion bottom panel A2 when the inner flap portion is in the folded position.

Folding and Assembly

The process of folding into a set-up position is illustrated step by step in FIGS. 58 to 60. This process can easily be reversed to unfold the boxes back to a flat pack position.

The base portion of the pack is folded (FIG. 58) in accordance with the steps described in respect of FIGS. 2 to 8.

Panel B, is then folded over such that the inner surface of panel B1 lies flat against A3, as shown in FIG. 59. The panel B1, in its folded position, will cover the panels D4 and D5, E4 and E5, so that they lie underneath panel B1 between B1 and A3.

The Panel B2, is then be pushed down so that it lies flat against the panel A2 as illustrated in FIG. 60. Panel B3 is folded up so that it lies diagonally across the box, thus forming a divider, as illustrated in FIG. 60.

The panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the panel A5 folding over the outer surface of A1, as illustrated by FIG. 60.

FIGS. 61 to 64 depict a tenth alternative embodiment and associated blank assembly of a collapsible pack of the invention and how it can be folded into a set up position by the user. In this example, a window panel/cut out is incorporated into the base second side wall E3, behind which a product image or description or other can be placed.

FIG. 64 shows the box in a flat state with the blank assembly fully formed. In this example the box consists of Panel A (made up of A1, A2, A3 which for the base of the box and panels A4 and A5 which in this example form the lid), Panel B (B1 and B2) which form the integral incorporated folding panel, Panel C which is also an integral folding panel, made of panel C1, Panels D and E (D1, D2, D3, D4, D5, E1, E2, E3, E4, E5 and E6) which form the side walls.

Folding and Assembly

The process of folding into a set-up position is illustrated step by step in FIGS. 61 to 63. This process can easily be reversed to unfold the boxes back to a flat pack position.

Side wall panel E3 has a rectangle cut out portion and a clear substrate (e.g. PVC) is glued to the back of the cut out to act as a window panel. FIG. 61 shows a piece of paper, which in this example has a product description that sits behind the window. Panel E6 is folded over to hold the paper in place, prior to the folding of panels B and C during set up.

The panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the panel A5 folding over the outer surface of A1.

Various alternative embodiments of the collapsible pack of the invention are shown in FIGS. 65 to 74. In particular,

FIGS. 65 and 66 show alternative versions of the pack with a window panel or cut out in the lid panel A4. A panel, window or cut out can be included on any panel or side of the box or lid, to act as an adornment, decoration, and feature or to allow visibility or access to the products.

FIG. 67 shows an alternative version of the box with extra panels D6 and E6 incorporated onto panel D and panel E to act as dust flaps to prevent the ingress of dust when the pack is in the assembled position.

FIG. 68 shows an alternative version of the box in different proportions and size with a carrying handle, and a string tie closure. In variations of this arrangement, a handle may be attached to a panel in various sizes and proportions. The invention could be made with other methods for carrying it attached to any location on the outer or inner surface, or carrying method not attached directly to the product. Attachments could also be added for as a feature or for decorative or adornment purposes to the outside or inside of this invention. A handle, made from a ribbon, string or other material could be affixed to the outer surface of panel A1 such that it passes through a cut, whole or slot in A5, or on any other panels, to act as a handle or adornment, or decoration or other use. FIG. 68 further shows an alternative closure for the lid, which in this example is held down by a piece of string attached to A5, which is wrapped around a tag affixed to the outer surface of A1.

FIG. 69 shows an alternative version of the box in different proportions and size with a carrying handle. The size and proportions of the pack and the corresponding position of the carrying handle will depend upon the purpose and use of the pack. For example, FIG. 70 shows an alternative version of the box in different proportions and size with a carrying handle.

FIGS. 71 to 74 illustrate various alternative versions of the pack of the invention with alternative methods for holding the lid (in this example parts A4 and A5) closed. The examples include the use of magnets (FIG. 74), ribbons (FIG. 73), studs clips, locks, Velcro and straps.

FIG. 71 shows an alternative version of the one-piece box closed with a lock holding the lid shut. FIG. 72 shows an alternative version of the one-piece box closed with a tag closure. FIG. 73 shows an alternative version of the one-piece box closed with ribbon closure. FIG. 74 shows an alternative version of the one-piece box closed with a magnet holding the lid shut.

Various other changes and modifications are envisaged, such as for example, there are a number of ways in which an insert may be integrated into a pack according to the invention, including altering the size, shape and number of panels, adding flaps, parts, cuts or interlocks to create an integrated insert. Some additional examples of alternatives for integrated inserts include fitments made using more incorporated integral panels, flaps, interlocks, cut outs, slots, holes and slits. In these examples, the fitment can also be flat packed, and is directly connected to the panels of the pack.

More panels can be incorporated, or part of the panels may be altered in size or structure, on the pack. Further panels, or parts, can also be incorporated to the existing panels and flaps which may also be changed in size and or structure.

This invention can also be made by altering the panel B2 or incorporating more panels, flaps, parts, cuts or interlocks so that the invention is held together in an erect set up position without the need for the panel B2 to touch or lie flat against the inner surface of the panel.

The base and lid could also be lined on the inside or the outside with material for decorative purposes or to protect the contents when in a set-up position. The base and lid could be lined with fabric material, for example.

The panels making up the compartment may be integrated with inner flap panel B2, as an extension of panel B2 or it may be incorporated to the other panels that make up the box and lid, or new panels or flaps incorporated to the box. Additional incorporated panels may act as an integrated compartment when folded in the set-up position. More panels can be integrated to form a combination of compartments and fitments. Alternative methods for holding the lid closed are also envisaged. Examples include the use of magnets, ribbons, studs clips, locks, Velcro and straps, or the like.

The collapsible pack of the invention is re-foldable so that it may be assembled and disassembled repeatedly by a user. The pack may be used to contain many different and varied products such as footwear, bottles, clothing, jewelry, wallets or the like. In this way, the pack is multifunctional and has the advantage that, in its collapsed form it is capable of flat-packing and also a quick fold erect process.

The one piece box and lid incorporating an integral internal panel or panels in the form of an inner flap portion allows the base of the box to be held erected in a set up position by the folded incorporated integral internal panels whether or not the attached lid is open or closed, without the use of additional glue, adhesives, tape, clip, or other fastener.

The pack is preferred to have a folding lid, folding side walls and incorporated integral internal folding panels, in which the lid, integral internal panels and side walls are attached to the main body of the box, and all are foldable such that the structure folds to form a fully covered complete box with attached lid (and not a box comprised of a separate lid and base parts).

Furthermore, the box can be assembled from the flat pack position to the set-up position and the box can be disassembled and returned to the flat pack position, without the use of adhesives, double sided tape, tape, or other fastener to hold it in the set-up position.

In preferred embodiments, the lid, side walls, base and internal panels are made flexible and foldable through the use of materials that have been pre-cut, pre-creased, pre-folded, or through by connecting the panels making up the sides and parts of the box with a flexible material, which may be a thicker or thinner substrate, or may connect the panels totally to each other or in part.

The box, lid and integral panels can be of varying dimensions, proportions, and sizes.

Further, any part of the box, lid or integral panels may have a window, slot, cut out or panel or may have part of the material replaced by a different material which is clear, see-through or not see-through to act as a window, or adornment or decoration, or access to the product.

A carrying mechanism, handle or part by which the box can be carried may be added to any of the internal or external panels, including but not limited to a ribbon, string, plastic, paper or metal handle affixed to the box.

When the lid is in a closed arrangement, the lid can be held in position by magnets, a ribbon, a clip, a slotting method, or other such method for securing the position of the lid of the box when in a set-up arrangement, or the lid can be left open and unattached.

The internal inner flap portion panels hold the box in an erect set up position by a fold erect mechanism of internal panels or by engaging frictionally, via slots or cuts in either flap, via a clip, or magnet, or by altering the shape of the panels or by interlocking between panels of the box, including more incorporated panels.

The internal flaps or panels may act as a fitment/insert. The internal flaps may have additional panels, flaps or material attached to them to support a product as a fitment, or to act as an adornment or decoration.

The internal flaps may have panels attached to them, or material cut out from them or the size or shape alerted in order to support a product as a fitment, or to act as an adornment or decoration.

The internal flaps may have additional panels, flaps or material attached to form a compartment or multiple compartments.

Part or all of the materials may be lined or coated with fabric or other materials, or various materials are used to make up the parts of the box.

The integral inner flap panel or panels may be fixed permanently in a set up position the use of additional glue, adhesives, tape, clip, or other fastener, or interlocking, clips or other method for permanently holding the box in a set-up position. 

1. A collapsible pack comprising a base portion, a lid portion and an inner flap portion, the base portion comprising a bottom panel, opposing front and rear panels and opposing side walls wherein the front panel, rear panel and the side walls are each hingedly connected to the bottom panel, the lid portion comprising a top panel, and the inner flap portion comprising a rear panel, wherein the inner flap portion and the lid portion are each hingedly connected to the base portion rear panel.
 2. A collapsible pack according to claim 1, wherein the lid portion top panel is hingedly connected to the base portion rear panel.
 3. A collapsible pack according to claim 1, wherein, during assembly of the pack, the inner flap portion rear panel is folded about the hinge line connecting same to the base portion rear panel so as to cover the base portion rear panel.
 4. A collapsible pack according to claim 1, wherein the inner flap portion rear panel is hingedly attached to the base portion rear panel.
 5. A collapsible pack according to claim 1, wherein the inner flap portion rear panel is hingedly attached to, or proximate to, an edge of the base portion rear panel.
 6. A collapsible pack according to claim 5, wherein when hingedly attached proximate to an edge of the base portion rear panel, the inner flap portion rear panel is attached to the inner face of the base portion rear panel.
 7. A collapsible pack according to claim 1, wherein the lid portion further comprises a side panel hingedly connected to the lid portion top panel.
 8. A collapsible pack according to claim 1, wherein the inner flap portion further comprises a bottom panel hingedly connected to the inner flap portion rear panel.
 9. A collapsible pack according to claim 8, wherein the inner flap portion bottom panel is hingedly connected to a free edge of the inner flap portion rear panel, which free edge is opposite the edge of the inner flap portion rear panel hingedly connected to the base portion rear panel.
 10. A collapsible pack according to claim 8, wherein during assembly of the pack, the inner flap portion bottom panel is folded about the hinge line connecting same to the inner flap portion rear panel so as to lie against the base portion bottom panel.
 11. A collapsible pack according to claim 1, wherein the pack further comprises a base portion inner front panel.
 12. A collapsible pack according to claim 11, wherein the base portion inner front panel is hingedly connected to the base portion front panel.
 13. A collapsible pack according to claim 1, further comprising first, second, third and fourth pairs of base side wall flaps.
 14. A collapsible pack according to claim 13, wherein each pair of base side wall flaps depends from an edge of a base side wall of the pack.
 15. A collapsible pack according to claim 13, wherein a first base side wall flap of each pair of base side wall flaps depends directly from an edge of a base side wall and a second base side wall flap of each pair depends from the other base side wall flap of the same pair.
 16. A collapsible pack according to claim 15, wherein the second base side wall flap of each pair of base side wall flaps depends from the first base side wall flap of a pair along a diagonal hinge line between diagonally opposed vertices of the connected pair of base side wall flaps.
 17. A collapsible pack according to claim 16, wherein one of the pair of base wall side flaps depends from an edge of a base portion side wall and the other of the pair from the diagonal hinge line.
 18. A collapsible pack according to claim 1, wherein the opposing base portion side walls are hingedly attached to the base portion bottom panel.
 19. A collapsible pack according to claim 18, wherein the opposing base portion side walls are hingedly attached to, or proximate to, opposing side edges of the base portion bottom panel.
 20. A collapsible pack according to claim 1, further comprising a second lid portion top panel.
 21. A collapsible pack according to claim 20, wherein the second lid portion top panel is hingedly connected to the base portion front panel.
 22. A collapsible pack according to claim 1, wherein the base portion front panel is further hingedly connected to a base portion inner front panel.
 23. A collapsible pack according to claim 1, wherein the lid and the base portion panels share a common longitudinal axis in the collapsed (flat) pack.
 24. A collapsible pack according to claim 1, wherein the inner flap portion panels are connected to one another along a hinge line.
 25. A collapsible pack according to claim 1, wherein the panels of the base portion and the panels of the lid portion are each and all separate from one another.
 26. A collapsible pack according to claim 1, wherein some or all of the panels of the base portion and/or some or all of the panels of the lid portion are connected to one another.
 27. A collapsible pack according to claim 1, wherein some or all of the panels of the base portion and lid portion are formed integrally with one another.
 28. A collapsible pack according to claim 1, further comprising at least one cover layer.
 29. A collapsible pack according to claim 28, wherein the at least one cover layer is a flexible material.
 30. A collapsible pack according to claim 28, wherein the cover layer is a flexible paper-based material.
 31. A collapsible pack according to claim 27, wherein the at least one cover layer has an adhesive coating applied to one surface thereof.
 32. A collapsible pack according to claim 28, wherein the at least one cover layer provides the hinge connections between adjacent panels/walls/flaps.
 33. A collapsible pack according to claim 28, wherein one or more of the panels of the base portion and the panels of the lid portion are connected by the cover layer.
 34. A collapsible pack according to claim 33, wherein the base portion bottom, front and rear panels, and the lid portion top panel, are covered by the at least one cover layer.
 35. A collapsible pack according to claim 28, wherein the inner flap portion further comprises a second cover layer.
 36. A collapsible pack according to claim 35, wherein the outer surface of the inner flap portion rear panel and, where present, the inner flap portion top panel, are covered by the second cover layer.
 37. A collapsible pack according to claim 35, wherein the inner flap portion rear panel is hingedly connected to the base portion rear panel by the second cover layer.
 38. A collapsible pack according to claim 1, wherein each panel is covered at least one cover layer.
 39. A collapsible pack according to claim 1, further comprising an insert.
 40. A collapsible pack according to claim 39, wherein the insert is formed by an extension to or, as an additional panel attached to, one or more of the panels or walls of the pack.
 41. A collapsible pack according to claim 39, wherein one or both of the base side walls comprises at least one additional panel forming an insert.
 42. A collapsible pack according to claim 39, further comprising a removable insert.
 43. A collapsible pack according to claim 1, further comprising a closure member.
 44. A collapsible pack according to claim 1, further comprising a window in a side wall thereof.
 45. A collapsible pack according to claim 1, further comprising a window in a lid and/or a base panel thereof.
 46. A blank assembly erectable into a collapsible pack, the blank assembly comprising: an outer blank having first and second major panels interconnected along hinge lines by a first minor panel and further having a second minor panel depending from the first major panel along a further hinge line; a first inner blank comprising a first minor panel; and a second and a third inner blank each comprising a first major panel and a first and a second minor panel depending from opposing edges of the major panel.
 47. A blank assembly according to claim 46, further comprising a third minor panel depending from the second major panel.
 48. A blank assembly according to claim 46, further comprising a fourth minor panel depending from the second minor panel along a further hinge line.
 49. A blank assembly according to claim 46, further comprising a fifth minor panel depending from the outer blank second minor panel along a further hinge line.
 50. A blank assembly according to claim 46, wherein the inner blank further comprises a first major panel depending from the first minor panel of the inner blank along a hinge line.
 51. A blank assembly according to claim 46, wherein the panels, flaps and walls are formed of a rigid material.
 52. A blank assembly formable into the collapsible pack of Claim
 1. 